Compressor carrier

8/20/2019 Compressor carrier

1/115

Container Refrigeration

T-318 Rev A

OPERATION AND SERVICE

for

69NT40-541-300 TO 399Container Refrigeration Units

r


2/115

OPERATION AND SERVICE MANUALCONTAINER REFRIGERATION UNIT

Models

69NT40-541-300 to 399


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TABLE OF CONTENTS -- Continued

PARAGRAPH NUMBER Page

DESCRIPTION 2--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 GENERAL DESCRIPTION 2--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Refrigeration Unit -- Front Section 2--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Fresh Air Makeup Vent 2--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.3 Evaporator Section 2--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.4 Compressor Section 2--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.5 Air-cooled Condenser Section 2--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.6 Water-Cooled Condenser Section 2--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.7 Control Box Section 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.8 Communications Interface Module 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 REFRIGERATION SYSTEM DATA 2--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 ELECTRICAL DATA 2--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 SAFETY AND PROTECTIVE DEVICES 2--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 REFRIGERATION CIRCUIT 2--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MICROPROCESSOR 3--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 3--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Keypad 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2 Display Module 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.3 Controller 3--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 CONTROLLER SOFTWARE 3--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Configuration Software (Configuration Variables) 3--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Operational Software (Function Codes) 3--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 MODES OF OPERATION 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Temperature Control -- Perishable Mode 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Evaporator Fan Operation 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Defrost Interval 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4 Failure Action 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5 Generator Protection 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.6 Condenser Pressure Control 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.7 Arctic Mode 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.8 Perishable Mode -- Conventional 3--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.9 Perishable Mode -- Economy 3--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.10 Perishable Mode -- Dehumidification 3--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.11 Perishable, Dehumidification -- Bulb Mode 3--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.12 Temperature Control -- Frozen Mode 3--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.13 Frozen Mode -- Conventional 3--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.14 Frozen Mode -- Economy 3--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 CONTROLLER ALARMS 3--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 UNIT PRE-TRIP DIAGNOSTICS 3--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 DataCORDER 3--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.1 Description 3--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.2 DataCORDER Software 3--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.3 Sensor Configuration (dCF02) 3--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.4 Logging Interval (dCF03) 3--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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3.6.5 Thermistor Format (dCF04) 3--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.6 Sampling Type (dCF05 & dCF06) 3--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.7 Alarm Configuration (dCF07 -- dCF10) 3--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.8 DataCORDER Power-Up 3--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.9 Pre-Trip Data Recording 3--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.10 DataCORDER Communications 3--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.11 USDA Cold Treatment 3--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.12 USDA Cold Treatment Procedure 3--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.13 DataCORDER Alarms 3--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 INSPECTION (Before Starting) 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 CONNECT POWER 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Connection To 380/460 VAC Power 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Connection to190/230 VAC Power 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 ADJUST FRESH AIR MAKEUP VENT 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Upper Fresh Air Makeup Vent 4--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2 Lower Fresh Air Makeup Vent 4--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 Fresh Air Position Sensor 4--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 CONNECT WATER-COOLED CONDENSER 4--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Water-Cooled Condenser with Water Pressure Switch 4--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 Water-Cooled Condenser with Condenser Fan Switch 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 CONNECT REMOTE MONITORING RECEPTACLE 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 STARTING AND STOPPING INSTRUCTIONS 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Starting the Unit 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.2 Stopping the Unit 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 START-UP INSPECTION 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.1 Physical Inspection 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2 Check Controller Function Codes 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.3 Start Temperature Recorder 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.4 Complete Inspection 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 PRE-TRIP DIAGNOSIS 4--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 OBSERVE UNIT OPERATION 4--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1 Crankcase Heater 4--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2 Probe Check 4--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10 SEQUENCE OF OPERATION 4--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.1 Sequence of Operation -- Perishable Mode Cooling 4--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.2 Sequence of Operation -- Perishable Mode Heating 4--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.3 Sequence of Operation -- Frozen Mode Cooling 4--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.4 Sequence of Operation -- Defrost 4--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11 EMERGENCY OPERATION 4--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11.1 Emergency Bypass Operation 4--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11.2 Emergency Defrost Operation 4--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12 ARCTIC MODE 4--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 5--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 UNIT WILL NOT START OR STARTS THEN STOPS 5--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 5--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING 5--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 5--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 UNIT WILL NOT TERMINATE HEATING 5--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 UNIT WILL NOT DEFROST PROPERLY 5--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7 ABNORMAL PRESSURES (COOLING) 5--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 ABNORMAL NOISE OR VIBRATIONS 5--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 CONTROLLER MALFUNCTION 5--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 5--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION 5--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.12 AUTOTRANSFORMER MALFUNCTION 5--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH 5--4. . . . . . . . . . . . . . . . . . . . . . . .

SERVICE 6--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 SECTION LAYOUT 6--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 SERVICE VALVES 6--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 MANIFOLD GAUGE SET 6--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 PUMPING THE UNIT DOWN 6--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 REFRIGERANT LEAK CHECKING 6--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 EVACUATION AND DEHYDRATION 6--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1 General 6--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.2 Preparation 6--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.3 Procedure - Complete System 6--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.4 Procedure - Partial System 6--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 REFRIGERANT CHARGE 6--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7.1 Checking the Refrigerant Charge 6--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7.2 Adding Refrigerant to System (Full Charge) 6--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7.3 Adding Refrigerant to System (Partial Charge) 6--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 COMPRESSOR 6--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.1 Removal and Replacement of Compressor 6--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.2 Compressor Disassembly 6--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.3 Compressor Reassembly 6--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.4 Preparation 6--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.5 Installing the Components 6--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8.6 Compressor Oil Level 6--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 HIGH PRESSURE SWITCH 6--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.1 Replacing High Pressure Switch 6--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9.2 Checking High Pressure Switch 6--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 CONDENSER COIL 6--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 CONDENSER FAN AND MOTOR ASSEMBLY 6--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12 WATER-COOLED CONDENSER CLEANING 6--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13 FILTER-DRIER 6--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14 THERMOSTATIC EXPANSION VALVE 6--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.1 Checking Superheat 6--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.2 Expansion Valve Replacement 6--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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6.15 EVAPORATOR COIL AND HEATER ASSEMBLY 6--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15.1 Evaporator Coil Replacement 6--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15.2 Evaporator Heater Replacement 6--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16 EVAPORATOR FAN AND MOTOR ASSEMBLY 6--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16.1 Replacing the Evaporator Fan Assembly 6--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16.2 Disassemble the Evaporator Fan Assembly 6--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16.3 Assemble the Evaporator Fan Assembly 6--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17 EVAPORATOR FAN MOTOR CAPACITOR 6--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17.1 When To Check For A Defective Capacitor 6--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17.2 Removing the Capacitor 6--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17.3 Checking the Capacitor 6--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18 SUCTION MODULATION VALVE 6--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18.1 Pre-check Procedure 6--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18.2 Checking the Stepper Valve 6--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18.3 Checking the Controller 6--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18.4 Emergency Repair Procedures 6--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.19 DPRV CHECK PROCEDURE 6--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.20 AUTOTRANSFORMER 6--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21 CONTROLLER 6--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21.1 Handling Controller 6--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21.2 Controller Troubleshooting 6--19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21.3 Controller Programming Procedure 6--19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21.4 Removing and Installing the Controller 6--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.21.5 Battery Replacement 6--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.22 TEMPERATURE SENSOR SERVICE 6--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.22.1 Sensor Checkout Procedure 6--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.22.2 Sensor Replacement 6--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.22.3 Sensor Re-Installation 6--21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.23 VENT POSITION SENSOR (VPS) 6--22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24 ELECTRONIC PARTLOW TEMPERATURE RECORDER 6--23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.1 Replacing the Recorder 6--23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.2 Changing the Chart 6--23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.3 Adjusting the Recorder Stylus 6--24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.4 Rezeroing the Recording Thermometer 6--24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.5 Rezeroing the Recording Thermometer 6--25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.25 MAINTENANCE OF PAINTED SURFACES 6--25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.26 COMPOSITE CONTROL BOX REPAIRS 6--25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.27 COMMUNICATIONS INTERFACE MODULE INSTALLATION 6--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.28 POWER FACTOR CORRECTOR CAPACITORS (PFC) 6--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING SCHEMATIC 7--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 INTRODUCTION 7--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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FIGURE NUMBER Page

Figure 2-1 Refrigeration Unit -- Front Section 2--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-2 Evaporator Section -- Units With Center Access Panel 2--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-3 Compressor Section 2--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-4 Condenser Section 2--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-5 Water-Cooled Condenser Section 2--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-6 Control Box Section 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 2-7 Refrigeration Circuit Schematic 2--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-1 Temperature Control System 3--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-2 Keypad 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-3 Display Module 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-4 Micro-Link 3 Controller 3--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-5 Standard Configuration Report 3--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-6 Data Reader 3--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-1 Autotransformer 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-2 Make Up Air Flow Chart 4--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-3 Controller Operation -- Perishable Mode 4--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 4-4 Controller Operation -- Frozen Mode 4--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-5 Perishable Mode Cooling 4--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-6 Perishable Mode Heating 4--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-7 Frozen Mode 4--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-8 Defrost 4--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-1 Service Valve 6--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-2 Manifold Gauge Set 6--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-3 R-134a Manifold Gauge/Hose Set 6--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-4 Refrigeration System Service Connections 6--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-5 Compressor Service Connections 6--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-6 Compressor 6--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-7 Exploded View of Valve Plate 6--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-8 Bottom Plate Removed 6--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-9 Oil Pump and Bearing Head 6--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-10 Low Profile Oil Pump 6--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-11 Motor End Cover 6--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-12 Equalizing Tube and Lock Screw Assembly 6--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-13 Crankshaft Assembly 6--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-14 Suction Valve & Positioning Springs 6--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-15 Piston Ring 6--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-16 High Pressure Switch Testing 6--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-17 Water-Cooled Condenser Cleaning -- Forced Circulation 6--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-18 Water Cooled Condenser Cleaning - Gravity Circulation 6--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-19 Thermostatic Expansion Valve Bulb 6--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-20 Thermostatic Expansion Valve 6--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-21 Hermetic Thermostatic Expansion Valve Brazing Procedure 6--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-22 Hermetic Thermostatic Expansion Valve Bulb Location 6--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-23 Evaporator Fan Assembly 6--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-24 Suction Modulation Valve (SMV) 6--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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FIGURE NUMBER Page

Figure 6-25 DPRV Replacement Value Chart 6--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-26 Controller Section of the Control Box 6--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-27 Sensor Types 6--21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-28 Sensor and Cable Splice 6--21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-29 Supply Sensor Positioning 6--22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-30 Return Sensor Positioning 6--22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-31 Electronic Partlow Temperature Recorder 6--24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-32 Door Hinge Repair 6--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-33 Insert Location 6--27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-34 Communications Interface Installation 6--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-35 R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature 6--32. . . . .

Figure 6-35 R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature 6--33. . . . .

Figure 7-1 Legend 7--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-2 SCHEMATIC DIAGRAM -- Units with Normal Evaporator Fan Capability 7--3. . . . . . . . . . . . . . . . . . . .

Figure 7-3 SCHEMATIC DIAGRAM -- Units with Single Evaporator Fan Capability 7--4. . . . . . . . . . . . . . . . . . . .

Figure 7-4 SCHEMATIC DIAGRAM -- TransFRESH and Vent Position Sensors (VPS) 7--5. . . . . . . . . . . . . . . . .

Figure 7-5 SCHEMATIC DIAGRAM -- Emergency Bypass 7--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-6 SCHEMATIC DIAGRAM, WIRING DIAGRAM -- Electronic Partlow Recorder 7--7. . . . . . . . . . . . . . .

Figure 7-7 UNIT WIRING DIAGRAM -- Units with Normal Evaporator Fan Capability 7--8. . . . . . . . . . . . . . . . . .

Figure 7-8 UNIT WIRING DIAGRAM -- Units with Single Evaporator Fan Capability 7--10. . . . . . . . . . . . . . . . . . .

LIST OF TABLES

TABLE NUMBER Page

Table 2-1 Safety and Protective Devices 2--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-1 Keypad Function 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-2 DataCORDER Configuration Variables 3--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-3 DataCORDER Standard Configurations 3--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-4 Controller Configuration Variables 3--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-5 Controller Function Codes 3--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-6 Controller Alarm Indications 3--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-7 Controller Pre-Trip Test Codes 3--21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-8 DataCORDER Function Code Assignments 3--25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-9 DataCORDER Pre-Trip Result Records 3--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-10 DataCORDER Alarm Indications 3--27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 6-1 Sensor Temperature/Resistance Chart 6--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-2 Crack, Chip & Hole Repair Kit 6--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-3 Insert Repair Kit 6--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-4 Drill Information 6--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-5 Recommended Bolt Torque Values 6--29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-6 Wear Limits For Compressors 6--29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-7 Compressor Torque Values 6--30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-8 R-134a Temperature - Pressure Chart 6--31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


10/115

T-318Safety--1

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in thismanual. They are recommended precautions that must be understood and applied during operation andmaintenanceof the equipment covered herein. The general safety notices are presented in the following three sections labeled:First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautionsappearing elsewhere in the manual follows the general safety notices.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

OPERATING PRECAUTIONS

Always wear safety glasses.

Keep hands, clothing and tools clear of the evaporator and condenser fans.

No work should be performed on the unit until all circuit breakers, start-stop switches areturned off, and power supplyis disconnected.

Always work in pairs. Never work on the equipment alone.

In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS

Beware of unannounced starting of the evaporator and condenser fans. Do not open the condenser fan grille orevaporator access panels before turning power off, and disconnecting and securing the power plug.

Be sure power is turned off before working on motors, controllers, solenoid valves, and electrical control switches. Tagcircuit breaker and power supply to prevent accidental energizing of circuit.

Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems withthe system should be diagnosed and any necessary repairs performed by qualified service personnel.

When performing any arc welding on the unit or container, disconnect all wire harness connectors from the modules inboth control boxes. Do not remove wire harness from the modules unless you are grounded to the unit frame with astatic safe wrist strap.

In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).

UNIT LABEL IDENTIFICATION

To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation isgiven with the appropriate consequences:

DANGER -- Indicates an immediate hazard that WILL result in severe personal injury or death.

WARNING -- Warns against hazards or unsafe conditions which COULD result in severe personal injury or death.

CAUTION -- Warns against potentially hazardous or unsafe practices that could result in minor personal injury, productor property damage.


11/115


12/115

T-318Safety--3

WARNING

With power OFF discharge the capacitorbefore disconnecting the circuit wiring.

WARNING

The unit power plug must be disconnectedto remove power from circuit breaker CB1

WARNING

Make sure power to the unit is OFF and

power plug disconnected before removing

capacitor(s).

WARNING

Before removing the capacitors, the

terminals must be checked for voltage with

a multimeter. The discharge resistors

installed on the unit (capacitors) should

bring the voltage to a safe level in a minute.

However, there may be a broken resistor

that retains voltage for a longer period.

Therefore, it is highly recommended to wait

15 minutes and to check for voltage.

CAUTION

Do not remove wire harnesses from con-

troller unless you are grounded to the unitframe with a static safe wrist strap.

CAUTION

Unplug all controller wire harness connec-tors before performing arc welding on anypart of the container.

CAUTION

Pre-trip inspection should not be per-formed with critical temperature cargoes in

the container.

CAUTION

When Pre-Trip key is pressed, dehumidifi-cation and bulb mode will be deactivated.At the completion of Pre-Trip activity, dehu-midification and bulb mode must be reacti-

vated.

CAUTION

When condenser water flow is below 11 lpm

(3 gpm) or when water-cooler is not in use,the CFS switch MUST be set to position “I”or the unit will not operate properly.

CAUTION

Pre-trip inspection should not be per-

formed with critical temperature cargoes inthe container.

CAUTIONWhen Pre-Trip key is pressed, dehumidifi-cation and bulb mode will be deactivated.At the completion of Pre-Trip activity, dehu-

midification and bulb mode must be reacti-vated.

CAUTION

When a failure occurs during automatic

testing, the unit will suspend operationawaiting operator intervention.

CAUTION

When Pre-Trip test Auto 2 runs to comple-tion without being interrupted, the unit willterminate pre-trip and display “Auto 2”“end.” The unit willsuspend operation untilthe user depresses the ENTER key!


13/115

Safety--4T-318

CAUTION

The unit will remain in thefull cooling mode

as long as the emergency bypass switch is

in the BYPASS position and the MODE

SWITCH is in the FULL COOL position. If

the cargo may be damaged by low tempera-

tures, the operator must monitor container

temperature and manually cycle operationas required to maintain temperature within

required limits.

CAUTION

The unit will remain in the DEFROST mode

as long as the emergency defrost switch isin the DEFROST position. To prevent cargo

damage, the operator must monitor con-tainer temperature and manually cycle op-

eration as required to maintain temperaturewithin required limits.

CAUTION

To prevent trapping liquid refrigerant in themanifold gauge set, be sure set is broughtto suction pressure before disconnecting.

WARNING

Before disassembly of any external com-pressor component, make sure to relievepossible internal pressure by loosening thebolts and tapping the component with a

soft hammer to break the seal.

CAUTION

Removing the compressor motor press-fitstator in the field is not recommended. The

rotor and stator are a matched pair andshould not be separated.

CAUTION

The copper tube that connects to the oilsuction strainer extends out the bottomwith the bottom plate removed. Take pre-cautions to avoid bending or breaking itwhile changing crankcase positions.

CAUTION

Ensure that the thrust washer does not falloff dowel pins while installing oil pump.

CAUTION

The set screw on the crankshaft must be

removed for this type of oil pump. (SeeFigure 6-9.)

CAUTION

Use only Carrier Transicold approvedPolyol Ester Oil (POE) -- Castrol-IcematicSW20 compressor oil with R-134a. Buy inquantities of one quart or smaller. When

using this hygroscopic oil, immediatelyreseal. Do not leave container of oil open orcontamination will occur.

CAUTION

Take necessary steps (place plywood overcoil or use sling on motor)to prevent motorfrom falling into condenser coil.

CAUTION

DO NOT disassemble piston from NEW suc-

tion modulating valve powerhead assem-bly. Doing so may result in damage to pis-ton.

CAUTION

Do not remove wire harnesses from con-troller unless you are grounded to the unitframe with a static safe wrist strap.

CAUTION

Unplug all controller connectors beforeperforming arc welding on any part of the

container.

CAUTION

The unit must be OFF whenever a program-ming card is inserted or removed from thecontroller programming port.


14/115

T-318Safety--5

CAUTION

Do not allow moisture to enter wire splicearea as this may affect the sensor resis-

tance.

CAUTION

Do not allow the recorder stylus to snapback down. The stylus arm base is

spring-loaded, and damage may occur tothe chart or the stylus force may be altered.

CAUTION

DO NOT move the stylus arm up and down

on the chart face. This will result in damageto the stylus motor gear.


15/115

1--1 T-318

SECTION 1

INTRODUCTION

1.1 INTRODUCTION

The Carrier Transicold model 69NT40-541-300/399series units are of lightweight aluminum frameconstruction, designed to fit in the front of a containerand serve as the container’s front wall.

They are one piece, self-contained, all-electric units,which includes cooling and heating systems to provideprecise temperature control.

The units are suppled with a complete charge of refrigerant R-134a and compressor lubricating oil, andare ready for operation upon installation. Forkliftpockets are provided for unit installation and removal.

The base unit operates on nominal 380/460 volt, 3phase, 50/60 hertz power. An optional autotransformermay be fitted to allow operation on nominal 190/230 , 3phase, 50/60 hertz power. Power for the control systemis provided by a transformer, which steps the supplypower down to 18 and 24 volts, single phase.

The controller is a Carrier Transicold Micro-Link 3

microprocessor. The controller will operateautomatically to select cooling, holding or heating asrequired to maintain the desired set point temperaturewithin very close limits. The unit may also be equippedwith a mechanical or electronic temperature recorder.

The controller has a keypad and display for viewing orchanging operating parameters. The display is alsoequipped with lights to indicate various modes of operation.

1.2 CONFIGURATION IDENTIFICATION

Unit identification information is provided on a platelocated near the compressor. The plate provides theunit model number, the unit serial number and the unitparts identification number (PID). The model numberidentifies the overall unit configuration while the PIDprovides information on specific optional equipment,factory provision to allow for field installation of optionalequipment and differences in detailed parts.

Configuration identification for the models coveredherein may be obtained on the Container ProductsGroup Information Center by authorized CarrierTransicold Service Centers.

1.3 OPTION DESCRIPTION

Various options may be factory or field equipped to thebase unit. These options are listed in the tables anddescribed in the following subparagraphs.

1.3.1 Battery

The refrigeration controller may be fitted with standardreplaceable batteries or a rechargeable battery pack.

1.3.2 Dehumidification

The unit may be fitted with a humidity sensor. Thissensor allows setting of a humidity set point in thecontroller. In the dehumidification mode the controllerwill operate to reduce internal container moisture level.

1.3.3 Control Box

Units are equipped with a composite material box andmay be fitted with a lockable door.

1.3.4 Display Module

The unit may be fitted with a backlit Liquid CrystaDisplay (LCD) or a Light Emitting Diode (LED) Display

1.3.5 Temperature Readout

The unit may be fitted with suction and discharge

temperature sensors. The sensor readings may beviewed on the controller display.

1.3.6 Pressure Readout

The unit may be fitted with suction and dischargepressure gauges, or suction and discharge transducersor no pressure readout. The transducer readings maybe viewed on the controller display.

1.3.7 USDA

The unit may be supplied with fittings for additionatemperature probes, which allow recording of USDACold Treatment data by the integral DataCORDERfunction of the Micro-Link refrigeration controller.

1.3.8 InterrogatorUnits that use the DataCORDER function are fitted withinterrogator receptacles for connection of equipment todownload the recorded data. Two receptacles may befitted; one accessible from thefront of the container andthe other mounted inside the container (with the USDAreceptacles).

1.3.9 Remote Monitoring

The unit may be fitted with a remote monitoringreceptacle. This item allows connection of remoteindicators for COOL, DEFROST and IN RANGEUnless otherwise indicated, the receptacle is mountedat the control box location

1.3.10 Communications.The unit may be fitted with a communications interfacemodule. The communications interface module is aslave module, which allows communication with amaster central monitoring station. The module wirespond to communication and return information overthe main power line. Refer to the ship master systemtechnical manual for further information.

1.3.11 Compressor

The unit is fitted with a single speed reciprocatingcompressor.

1.3.12 Condenser Coil

The unit is fitted with a 3--row coil using 7mm tubing.

1.3.13 Autotransformer

An autotransformer may be provided to allow operationon 190/230, 3 phase, 50/60 hertz power. Theautotransformer raises the supply voltage to thenominal 380/460 volt power required by the base unitThe autotransformer may also be fitted with anindividual circuit breaker for the 230 volt power.

If the unit is equipped with an autotransformer andcommunications module, the autotransformer will befitted with a transformer bridge unit (TBU) to assist incommunications.


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1--2T-318

1.3.14 Temperature Recorder

The units may be fitted with an electronic temperaturerecording device.

1.3.15 Gutters

Rain gutters may be fitted over the control box andrecorder section to divert rain away form the controls.The different gutters include standard length boltedgutters, extended length gutters, and riveted gutters.

1.3.16 Handles

The unit may be equipped with handles to facilitateaccess to stacked containers. These handles mayinclude fixed handles (located at the sides of the unit)and/or a hinged handle at the center (attached to thecondenser coil cover).

1.3.17 Thermometer Port

The unit may be fitted with ports in the front of the framefor insertion of a thermometer to measure supply and/orreturn air temperature. If fitted, the port(s) will require acap and chain.

1.3.18 Water Cooling

The refrigeration system may be fitted with awater-cooled condenser. The condenser is constructedusing copper-nickel tube for seawater applications. Thewater-cooled condenser is in series with the air-cooledcondenser and replaces the standard unit receiver.When operating on the water-cooled condenser, thecondenser fan can be deactivated by either a waterpressure switch or condenser fan switch. Depending onthe unit’s configuration and the compressor dischargetemperature, the condenser fan may also be activatedduring water-cooled condenser operation.

1.3.19 Back Panels

Back panel designs that may be fitted include panels of aluminum and stainless steel. Panels may have accessdoors and/or hinge mounting.

1.3.20 460 Volt CableVarious power cable and plug designs are available forthe main 460 volt supply. The plug options tailor thecables to each customers requirements.

1.3.21 230 Volt Cable

Units equipped with an autotransformer require anadditional power cable for connection to the 230 voltsource. Various power cable and plug designs areavailable. The plug options tailor the cables to eachcustomers requirements.

1.3.22 Cable Restraint

Various designs are available for storage of the powercables. These options are variations of the compressor

section front cover.1.3.23 Upper Air (Fresh Air Make Up)

The unit may be fitted with an upper fresh air makeupassembly. The fresh air makeup assembly is availablewith a vent positioning sensor (VPS) and may also befitted with screens.

1.3.24 Lower Air (Fresh Air Make Up)

The unit may be fitted with a lower fresh air makeupassembly. The fresh air makeup assembly is availablewith a vent positioning sensor (VPS) and may also befitted with screens.

1.3.25 Arctic Mode

To improve operation in cold ambients, the unit may befitted with a crankcase heater. The crankcase heater isoperated any time the unit is under power and thecompressor is not running. The purpose of the heater isto warm the compressor oil and boil off any liquidrefrigerant that may be present in the crankcase.

1.3.26 Power Correction

The unit may be fitted with a set of power factor

correction capacitors to assist in correction of imbalance in current draw by the compressor.

1.3.27 Evaporator

The evaporator section is equipped with a hermeticthermalexpansion valve anda heat exchanger. The unitmay have six heaters.

1.3.28 Evaporator Fan Operation

Two evaporator fan motor operation systems areavailable. On units with Normal Evaporator FanOperation, opening of an evaporator fan internalprotector will shut down the unit. On units equipped withSingle Evaporator Fan Capability, additional relays areinstalled to allow the unit to continue to operate on a

single fan.1.3.29 Labels

Operating instructionand function code listing labels willdiffer depending on the options installed. For example,additional operating instructions are required todescribe start-up of a unit equipped with anautotransformer. Where the labels are available withadditional languages, they are listed in the parts list.

1.3.30 Plate Set

Each unit is equipped with a tethered set of wiringschematic and wiring diagram plates. The plate sets areordered using a seven-digit base part number and atwo-digit dash number.

1.3.31 Controller

Two different controllers are available:1. Remanufactured -- Controller is the equivalent of anew OEM controller and is supplied with a 12 monthwarranty.2. Repaired -- Controller has had previous faultsrepaired and upgraded with the latest software.Note: Repaired controllers are NOT to be used forwarranty repairs. Only full OEM remanufacturedcontrollers are to be used.Controllers will be factory equipped with the latestversion of operational software, but will NOT beconfigured for a specific model number and will need tobe configured at the time of installation or sale.

1.3.32 Condenser Grille

Two styles of condenser grilles are available -- directbolted grilles and hinged grilles.

1.3.33 Emergency Bypass

The unit may be equipped with switches to allowemergency bypass of the controller. The EMERGENCYBYPASS switch functions to bypass thecontroller in theevent of controller failure. The EMERGENCYDEFROST switch functions to bypass all controls andplace the unit in the defrost mode.


17/115

T-3182--1

SECTION 2

DESCRIPTION

2.1 GENERAL DESCRIPTION

2.1.1 Refrigeration Unit -- Front Section

The unit is designed so that the majority of thecomponents are accessible from the front (see

Figure 2-1). The unit model number, serial number, and

parts identification number can be found on the seriaplate to the left of the compressor.

2.1.2 Fresh Air Makeup Vent

The function of the upper or lower makeup air vent is toprovide ventilation for commodities that require fresh ai

circulation.

1

2

5

3

4

9

12

6

13

11

7

10

8

1. Access Panel (Evaporator Fan #1)/ThermostaticExpansion Valve / HTT)

2. Fork Lift Pockets3. Control Box4. Compressor5. Unit Serial Number, Model Number, and

Parts Identification Number (PID) Plate6. Condenser Fan7. TransFRESH Communications Connector

8. Interrogator Connector (Front Left)9. Temperature Recorder10. Lower Fresh Air Makeup Vent Location

(Blank Cover Shown)11. TIR (Transports Internationaux Routiers)

Sealing Provisions - Typical All Panels12. Upper Fresh Air Makeup Vent13. Access Panel (Evaporator Fan #2)/ Humidity

Sensor / Return Temperature Sensor

Figure 2-1 Refrigeration Unit -- Front Section


18/115

T-318 2--2

2.1.3 Evaporator Section

The evaporator section (Figure 2-2) contains the returntemperature sensor, humidity sensor, thermostaticexpansion valve, dual-speed evaporator fans (EM1 andEM2), evaporator coil and heaters, defrost temperaturesensor, heat termination thermostat, and heatexchanger.

The evaporator fans circulate air through the containerby pulling it in the top of the unit, directing it through theevaporator coil where it is heated or cooled, anddischarging it at the bottom.

The evaporator components are accessible byremoving the upper rear panel (as shown in Figure 2-2).

1312

1011

1

2

3

4

5

7

9

14

15

6

8

TXV Bulb(under Insulation)

16

1. Evaporator Fan Motor #12. Return Recorder Sensor (RRS) / Return

Temperature Sensor (RTS)3. Humidity Sensor4. Evaporator Fan Motor #25. Defrost Temperature Sensor6. Heater Termination Thermostat7. Evaporator Coil8. Hermetic Thermostatic Expansion Valve

9. Heat Exchanger10. Interrogator Connector (Rear)

11. USDA Probe Receptacle PR212. USDA Probe Receptacle PR113. USDA Probe Receptacle PR314. Cargo Probe Receptacle PR415. Evaporator Coil Heaters16. TXV Bulb Routing

Figure 2-2 Evaporator Section -- Units With Center Access Panel


19/115

T-3182--3

2.1.4 Compressor Section

The compressor section includes the compressor (withhigh pressure switch), power cable storagecompartment, and autotransformer.

This section also contains the suction modulating valve,

discharge pressure regulating valve, dischargetemperature sensor, and discharge/suction pressuretransducers.

The supply temperature sensor, supply recordesensor, and ambient sensor are located at the right sideof the compressor.

11

12

1

2

3

4

56

7

9

10

1516

17

1819

22

20

21

13

14

8

1. Autotransformer2. Power Cables and Plug3. Compressor Sight Glass View Port4. Compressor Guard5. Supply Temperature Sensor6. Supply Recorder Sensor7. Ambient Sensor8 Supply Air Thermometer Port9. Discharge Service Valve

10. Discharge Temperature Sensor

11. Discharge Pressure Regulating Valve

12. Suction Temperature Sensor13. Quench Valve Temperature Bulb14. Quench Valve15. Access Valve16. Suction Modulating Valve17. Suction Service Valve18. Compressor Crankcase Heater19. Compressor Motor20. Suction Pressure Transducer21. High Pressure Switch

22. Discharge Pressure TransducerFigure 2-3 Compressor Section


20/115

T-318 2--4

2.1.5 Air-cooled Condenser Section

The air-cooled condenser section (Figure 2-4) consistsof the condenser fan, condenser coil, receiver with sightglass/moisture indicator, quench valve, manual liquid

line valve, filter-drier, condenser pressure transducer,and fusible plug.

The condenser fan pulls air in through the bottom of thecoil and discharges it horizontally out through thecondenser fan grille.

5

6

7

15

1

2 43

8

10

9

11

13

12

14

1. Grille and Venturi Assembly2. Condenser Fan3. Key4. Condenser Fan Motor5. Condenser Coil Cover6. Condenser Coil7. Condenser Motor Mounting Bracket8. Receiver

9. Sight Glass10. Fusible Plug (Rupture Disc -- Alternate)11. Condenser Pressure Transducer12. Sight Glass/Moisture Indicator13. Filter-Drier14. Liquid Line Service Valve15. Quench Valve

Figure 2-4 Condenser Section


21/115

T-3182--5

2.1.6 Water-Cooled Condenser Section

The water-cooled condenser section (Figure 2-5)consists of a water-cooled condenser, sight glass,

quench expansion valve, rupture disc, condensepressure transducer, filter-drier, water couplings, andwater pressure switch. The water-cooled condensereplaces the standard unit receiver.

1

2

3 4 5 6

7

8

9

1011

1. Sight Glass2. Water-Cooled Condenser3. Rupture Disc4. Condenser Pressure Transducer5. Quench Valve6. Filter-Drier

7. Liquid Line Service Valve8. Moisture/Liquid Indicator9. Coupling (Water In)

10. Self Draining Coupling (Water Out)11. Water Pressure Switch

Figure 2-5 Water-Cooled Condenser Section


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T-318 2--6

2.1.7 Control Box Section

The control box (Figure 2-6) includes the manualoperation switches, circuit breaker (CB-1), compressor,fan and heater contactors, control power transformer,fuses, keypad, display module, current sensor module,controller module and the communications interfacemodule.

2.1.8 Communications Interface Module

The communications interface module is a slavemodule, which allows communication with a mastercentral monitoring station. The module will respond tocommunication, and return information over the mainpower line. Refer to the master system technical manualfor further information.

161718 121415

1 2 3 4 5 6

710 919 11 8132021

1. Compressor Contactor2. Heater Contactor3. Display Module4. Communications Interface Module5. Controller/DataCORDER Module (Controller)

6. Key Pad7. Emergency Defrost Light8. Start-Stop Switch9. Remote Monitoring Receptacle

10. Manual Defrost Switch11. Condenser Fan Switch

12. Controller Battery Pack13. Interrogator Connector (Box Location)14. Control Transformer15. Evaporator Fan Contactor - E116. Evaporator Fan Contactor - S1

17. Evaporator Fan Contactor - S2 or EF18. Evaporator Fan Contactor - E2 or ES19. Condenser Fan Contactor20. Circuit Breaker -- 460V21. Current Sensor Module

Figure 2-6 Control Box Section


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T-3182--7

2.2 REFRIGERATION SYSTEM DATA

a. Compressor/MotorAssembly

Number of Cylinders 6

Model 06DR

CFM 41

Weight (Dry) 118 kg (260 lb)

Approved Oil Castrol Icematic

Oil Charge degrees 3.6 liters (7.6 U.S. pints)

Oil Sight Glass The oil level range, with the compressor off,should be between the bottom and one-eighthlevel of the sight glass.

b. Expansion Valve Superheat

Verify at -18 degreesC(0 degrees F) contain-er box temperature

4.5 to 6.7 C (8 to 12 F)

c. Heater Termination ThermostatOpens 54 (+/-) C = 130 (+/-) F

Closes 38 (+/- 4) C = 100 (+/- 7) F

d. High Pressure SwitchCutout 25 (+/- 1.0) kg/cm@ = 350 (+/- 10) psig

Cut-In 18 (+/- 0.7) kg/cm@ = 250 (+/- 10) psig

e. Refrigerant Charge

Unit ConfigurationCharge Requirements -- R-134a

3 row condenserWater-CooledCondenser 5.2 kg (11.5 lbs)

Receiver 4.9 kg (10.8 lbs)

NOTEWhen replacing the following components (f.), (g.) and (h.), refer to the installation instructions included with the

replacement part for additional information.

f. Fusible Plug* Melting point 99 C = (210 F)

Torque* 6.2 to 6.9 mkg (45 to 50 ft-lbs)

g. Sight Glass/Moisture Indicator Torque 8.9 to 9.7 mkg (65 to 70 ft-lbs)

h. Rupture Disc

Bursts at 35 +/- 5% kg/cm@ = (500 +/- 5% psig)

Torque

(P/N 14-00215-03) 1.4 to 2 mkg (10 to 15 ft-lbs)

i. Condenser PressureTransducer

Condenser Fan Starts

The condenser fan will start if the condenserpressure is greater than 14.06 kg/cm@ (200psig) OR the condenser fan is OFF for morethan 60 seconds.

Condenser Fan Stops

The condenser fan will stop if the condenserpressure is less than 9.14 kg/cm@ (130 psig) AND the condenser fan remains ON for at least30 seconds.

j. Unit Weight Refer to unit model number plate.

k. Water Pressure SwitchCut-In

0.5 +/- 0.2 kg/cm@

3-row condenser (7 +/- 3 psig)

Cutout 1.6 +/- 0.4 kg/cm@ (22 +/- 5 psig)l. Discharge Pressure

Regulating Valve Factory Setting 32.7 +/- 2.5 kg/cm@ (72+/- 5.5 psig)

* Rupture Disc, part number 14 -00215 -04 may be installed as an alternate for the receiver mounted fusible plug.


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T-318 2--8

2.3 ELECTRICAL DATA

a. Circuit Breaker

CB-1 Trips at 29 amps

CB-2 (50 amp) Trips at 62.5 amps

CB-2 (70 amp) Trips at 87.5 amps

b. CompressorMotor Full Load Amps (FLA)

17.6 amps @ 460 VAC(with current limiting set at 21 amps)

c. Condenser FanMotor

380 VAC, Single Phase,50 Hz

460 VAC, Single Phase,60 hz

Full Load Amps 1.3 amps 1.6 ampsHorsepower 0.43 hp 0.75 hp

Rotations Per Minute 1425 rpm 1725 rpm

Voltage and Frequency 360 -- 460 VAC +/- 2.5 hz 400 -- 500 VAC +/- 2.5 hz

Bearing Lubrication Factory lubricated, additional grease not required.

Rotation Counter-clockwise when viewed from shaft end.

d. Evaporator CoilHeaters

Number of Heaters 6

Rating 750 watts +5/ -10% each @ 230 VAC

Resistance (cold) 66.8 to 77.2 ohms @ 20 C (68 F)

Type Sheath

e. Evaporator FanMotor(s)

380 VAC/50 hz 460 VAC/60 hz

Full Load AmpsHigh Speed

1.6 2.0

Full Load AmpsLow Speed

0.8 1.0

Nominal HorsepowerHigh Speed

0.70 0.84

Nominal HorsepowerLow Speed

0.09 0.11

Rotations Per MinuteHigh Speed

2850 rpm 3450 rpm

Rotations Per MinuteLow Speed

1425 rpm 1750 rpm

Voltage and Frequency 360 -- 460 VAC +/- 1.25 hz 400 -- 500 VAC +/- 1.5 hz

Voltage & Frequency us-ing power autotransformer

180 -- 230 VAC +/- 1.25hz 200 -- 250 VAC +/- 1.5 hz

Bearing Lubrication Factory lubricated, additional grease not required

Rotation CW when viewed from shaft end

f. Fuses

Control Circuit 7.5 amps (F3A, F3B)

Controller/DataCORDER 5 amps (F1 & F2)

Emergency Defrost 5 amps (FED)

Drain Line Heater 5 amps (FDH)

Humidity PowerTransformer

5 amps (FH)

g. Compressor Crankcase Heater 180 watts @ 460 VAC


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T-3182--9

2.3 ELECTRICAL DATA (Continued)

h. Humidity Sensor

Orange wire Power

Red wire Output

Brown wire Ground

Input voltage 5 vdc

Output voltage 0 to 3.3 vdc

Output voltage readings verses relative humidity (RH) percentage:

30% 0.99 V

50% 1.65 V70% 2.31 V

90% 2.97 V

i. Controller Setpoint Range -30 to +30 C ( -22 to +86 F)

2.4 SAFETY AND PROTECTIVE DEVICES

Unit components are protected from damage by safety and protective devices listed in the following table. Thesedevices monitor the unit operating conditions and open a set of electrical contacts when an unsafe condition occurs

Table 2-1 Safety and Protective Devices

UNSAFE CONDITION SAFETY DEVICE DEVICE SETTING

Circuit Breaker (CB-1) -- Manual Reset Trips at 29 amps (460 VAC)

Excessive current draw Circuit Breaker (CB-2, 50 amp) --Manual Reset Trips at 62.5 amps (230

VAC)

Circuit Breaker (CB-2, 70 amp) --Manual Reset Trips at 87.5 amps (230

VAC)

Excessive current draw in thecontrol circuit Fuse (F3A & F3B) 7.5 amp rating

Excessive current draw by thecontroller Fuse (F1 & F2) 5 amp rating

Excessive current draw by theemergency defrost circuit Fuse (FED) 5 amp rating

Excessive condenser fan mo-tor winding temperature Internal Protector (IP-CM) -- Automatic Reset N/A

Excessive compressor motorwinding temperature Internal Protector (IP-CP) -- Automatic Reset N/A

Excessive evaporator fan mo-tor(s) winding temperature Internal Protector(s) (IP-EM) -- Automatic Reset N/A

Abnormal pressures/tempera-tures in the high refrigerantside

Fusible Plug -- Used on the Receiver

Rupture Disc -- Used on the Water-CooledCondenser

99 C = (210 F)

35 kg/cm@ = (500 psig)

Abnormally high discharge

pressure High Pressure Switch (HPS)

Opens at 25 kg/cm@

(350 psig)


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T-318 2--10

2.5 REFRIGERATION CIRCUIT

Starting at the compressor (see Figure 2-7, upperschematic), the suction gas is compressed to a higherpressure and temperature.

The gas flows through the discharge service valve intothe pressure regulating valve. During periods of lowambient operation, the discharge pressure regulatingvalve modulates the flow of refrigerant to maintain a pre-set minimum discharge pressure. Refrigerant gas then

moves into the air-cooled condenser. When operatingwith the air-cooled condenser active, air flowing acrossthe coil fins and tubes cools the gas to saturationtemperature. By removing latent heat, the gascondenses to a high pressure/high temperature liquidand flows to the receiver, which stores the additionalcharge necessary for low temperature operation.

When operating with the water-cooled condenser active(see Figure 2-7, lower schematic), the refrigerant gaspasses throughthe air-cooledcondenser and enters thewater-cooled condenser shell. The water flowing insidethe tubing cools the gas to saturation temperature in thesame manner as the air passing over the air-cooledcondenser. The refrigerant condenses on the outside of the tubes and exits as a high temperature liquid. The

water-cooled condenser also acts as a receiver, storingexcess refrigerant.

The liquid refrigerant continues through the liquid lineservice valve, the filter-drier (which keeps refrigerantclean and dry), and a heat exchanger (that increasessubcooling of the liquid) to the thermostatic expansionvalve. As the liquid refrigerant passes through thevariable orifice of the expansion valve, some of itvaporizes into a gas (flash gas). Heat is absorbed fromthe return air by the balance of the liquid, causing it tovaporize in the evaporator coil. The vapor then flowsthrough the suction modulatingvalve to thecompressor.

The thermostatic expansion valve is activated by thebulb strapped to the suction line near the evaporator

outlet. The valve maintains a constant superheat at thecoil outlet regardless of load conditions.

During periods of low load, the suction modulating valvedecreases flow of refrigerant to the compressor. Thisaction balances the compressor capacity with the loadand prevents operation with low coil temperatures. Inthis mode of operation, the quench valve will open asrequired to provide sufficient liquid refrigerant flow intothesuction line for cooling of the compressor motor. Thequench valve senses refrigerant condition entering thecompressor and modulates the flowto prevent entranceof liquid into the compressor.

The refrigeration system is also fitted with a condenserpressure transducer, which feeds information to thecontroller. When operating on the air-cooled condenser,the controller programming will operate the condenserfan so as to attempt to maintain discharge pressuresabove 130 psig in low ambients. At ambients below 27degrees C (80 degrees F), the condenser fan will cycleon and off depending on condenser pressure andoperating times.

1 The condenser fan will start if the condenser pres-sure is greater than 200 psig OR the condenser fanhas been OFF for more than 60 seconds.

2 The condenser fan will stop if the condenser pres-sure is less than 130 psig AND the condenser fanhas been running for at least 30 seconds.

At ambients above 27 C (80 F), condenser pressurecontrol is disabled and the condenser fan runscontinuously.

On systems fitted with a water pressure switch, thecondenser fan will be off when there is sufficientpressure to open the switch. If water pressure dropsbelow the switch cut out setting, the condenser fan willbe automatically started. When operating a systemfittedwitha condenser fanswitch, thecondenser fanwillbe off when the switch is placed in the “O” position. Thecondenser fan will be onwhen the switch is placed in the“I” position.


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T-3182--11

FILTER DRIER

TXV

TXV BULB

MODULATING VALVE

PRESSURE

TRANSDUCER

HEAT EXCHANGER

SIGHT GLASS

FILTER DRIER

HEAT EXCHANGER

MODULATING VALVE

PRESSURE

TRANSDUCER

SIGHT GLASS

FUSIBLE PLUG

RECEIVER

SERVICE VALVE

WATER-COOLED

CONDENSER

TXV

TXV BULB

EVAPORATOR

CONDENSER

PRESSURE TRANSDUCER

SERVICE VALVE

DISCHARGE PRESSURE

REGULATING VALVE

EVAPORATOR

CONDENSER

SERVICE VALVE

SERVICE VALVE

Circuit with Receiver

QUENCH VALVE

QUENCH VALVE

Circuit with Water-Cooled Condenser

FUSIBLE PLUG

SuctionLiquid

Discharge

Suction

Liquid

Discharge

DISCHARGE PRESSURE

REGULATING VALVE

Figure 2-7 Refrigeration Circuit Schematic


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T-3183--1

SECTION 3

MICROPROCESSOR

3.1 TEMPERATURE CONTROL MICROPRO-CESSOR SYSTEM

The temperature control Micro-Link 3 microprocessorsystem (see Figure 3-1) consists of a keypad, displaymodule, control module (controller), andinterconnecting wiring. The controller houses thetemperature control software and the DataCORDER

Software. The temperaturecontrolsoftware functions tooperate the unit components as required to provide thedesired cargo temperature and humidity. TheDataCORDER software functions to record unit

operating parameters and cargo temperatureparameters for future retrieval. Coverage of thetemperature control software begins with paragraph3.2. Coverage of the DataCORDER software isprovided in paragraph 3.6.

The keypad and display module serve to provide useraccess and readouts for both of the controller functions

temperature control, and DataCORDER. The functionsare accessed by keypad selections and viewed on thedisplay module. The components are designed topermit ease of installation and removal.

TODISPLAY

CONTROL MODULEDISPLAY MODULE

KEYPAD

CONFIGURATIONSOFTWARE

CONFIGURATION VARIABLE

(CnF##)

TEMPERATURE CONTROL SOFTWARE

ALARMS(AL68)

DATASTORAGEMEMORY

OPERATIONALSOFTWARE

FUNCTION

CODE (dC)

TODISPLAY

(Scrollback)

DATABANK CARD

Figure 3-1 Temperature Control System


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T-318 3--2

3.1.1 Keypad

The keypad (Figure 3-2) is mounted on the right-handside of the control box. The keypad consists of 11 pushbutton switches that act as the user’s interface with thecontroller. Descriptions of the switch functions areprovided in Table 3-1.

ENTER

BATTERY

POWER

MANUAL

DEFROST/

INTERVAL

CODE

SELECT

PRE

TRIP

ALARM

LIST

ALT.

MODE

RETURN

SUPPLY

_C

_F

Figure 3-2 Keypad

COOL HEAT DEFROST IN RANGEALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

Figure 3-3 Display Module

3.1.2 Display Module

The display module (Figure 3-3) consists of five digital

displays and seven indicator lights. The indicator lightsinclude:

1. Cool -- White LED: Energized when the refrigerantcompressor is energized.

2. Heat -- Orange LED: Energized to indicate heaterop-eration in the heat or defrost mode.

3. Defrost -- Orange LED: Energized when the unit is inthe defrost mode.

4. In-Range -- Green LED: Energized when the con-trolled temperatureprobe is within specified toleranceof set point.

Table 3-1 Keypad Function

KEY FUNCTION

Code Select Accesses function codes.

Pre-Trip Displays the pre-trip selection menu.

Discontinues pre-trip in progress.

Alarm List Displays alarm list and clears the

alarm queue.

Manual

Defrost/ Interval

Displays selected defrost mode. De-

pressing and holding the Defrost in-terval key for five seconds will initiatedefrost using the same logic as if theoptional manual defrost switch wastoggled on.

Enter Confirms a selection or saves a

selection to the controller

Arrow Up Change or scroll a selection upward

Pre-trip advance or test interruption.

Arrow Down Change or scroll a selection down-

ward. Pre-trip repeat backward

Return/ Supply

Displays non-controlling probe tem-perature (momentary display).

DegreesC/-Degrees F

Displays alternate English/Metricscale (momentary display). When setto degrees Fahrenheit, pressure isdisplayed in psig and vacuum in “/hg.“P” appears after the value to indi-cate psig and “i” appears for inchesof mercury.

When set to degrees Celsius, pres-sure readings are in bars. “b” ap-pears after the value to indicate bars.

BatteryPower

Initiate battery backup mode to allowset point and function code selectionif AC power is not connected.

ALT. Mode

This key is pressed to switch thefunctions from the temperature soft-ware to the DataCORDER Software.The remaining keys function thesame as described above except thereadings or changes are made to theDataCORDER programming.

NOTE

The controlling probe in the perishable rangewill be theSUPPLY air probe and thecontrollingprobe in the frozen range will be the RETURNair probe.

5. Supply -- Yellow LED: Energized when the supply air

probe is used for control. When this LEDis illuminated,the temperature displayed in the AIR TEMPERATUREdisplay is the reading at the supply air probe. ThisLEDwill flash if dehumidification or humidification is en-abled.

6. Return -- Yellow LED: Energized when the return airprobe is used for control. When this LEDis illuminated,the temperature displayed in the AIR TEMPERATUREdisplay is the reading at the return air probe. This LEDwill flash if dehumidification or humidification is en-abled.

7. Alarm -- Red LED: Energized when there is an activeor an inactive shutdown alarm in the alarm queue.


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T-3183--3

81 2 3 3 3 3 34 5 6 7

1. Mounting Screw2. Micro-Link 3

Controller3. Connectors4. Test Points

5. Fuses6. Control Circuit Power Connection

(Location: In back of controller)7. Software Programming Port8. Battery Pack

Figure 3-4 Micro-Link 3 Controller

3.1.3 Controller

CAUTIONDo not remove wire harnesses from con-troller unless you are grounded to the unitframe with a static safe wrist strap.

CAUTION

Unplug all controller wire harness connec-tors before performing arc welding on anypart of the container.

NOTE

Do not attempt to service the controller. Break-ing the seal will void the warranty.

NOTE

Do not attempt to use an ML2i PC card in anML3equippedunit. The PC cards arephysicallydifferent and will result in damageto the control-ler.

The Micro-Link 3 controller is a single modulemicroprocessor as shown in Figure 3-4. It is fitted withtest points, harness connectors and a software cardprogramming port.

3.2 CONTROLLER SOFTWAREThe controller software is a custom designed programthat is subdivided intothe configuration software andtheoperational software. The controller software performsthe following functions:

a. Control supply or return air temperature to requiredlimits, provide modulated refrigeration control, elec-tric heat control and defrost. Defrost is performed toclear buildup of frost and ice from the coil to ensurecontinuous conditioned air delivery to the load.

b. Provide default independent readouts of set point andsupply or return air temperatures.

c. Provide ability to read, and if applicable, modify theconfiguration software variables, operating softwarefunction codes, and alarm code indications.

d. Provide a pre-trip step-by-step checkout of refrigeration unit performance, including proper componentoperation, electronic and refrigeration control operation, heater operation, probe calibration, pressurelimiting, and current limiting settings.

e. Provide battery-powered ability to access or changeselected codes and set points without AC power connected

f. Provide the ability to reprogram the software throughthe use of a memory card.

3.2.1 Configuration Software (Configuration Vari-ables)

The configuration software is a variable listing of thecomponents available for use by the operationasoftware. This software is factory-installed inaccordance with the equipment fitted and options listedon the original purchase order. Changes to theconfiguration software are required only when theoriginal softwarehas been lost or a physical change hasbeen made to theunit, such as theaddition or removal oan option. A configuration variable list is provided inTable 3-4 (page 3--13). A change to the factory-installedconfiguration software is achieved via a configurationcard.

3.2.2 Operational Software (Function Codes)

The operational software is the actual operationprogramming of the controller, which activates odeactivatescomponents in accordance with current unioperation conditions and operator selected modes ooperation.

The programming is divided into function codes. Someof the codes are read only while the remaining codesmay be user configured. The value of the useconfigurable codes can be assigned in accordance withuser desired mode of operation. A list of the functioncodes is provided in Table 3-5 (page 3--14)


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T-318 3--4

To access the function codes, perform the following:

a. Press the CODE SELECT key, then press an arrowkey until the left window displays the desired codenumber.

b. The right window will display the value of this item forfive seconds before returning to the normal displaymode.

c. If a longer time is desired, press the ENTER key to ex-tend the time to 30 seconds.

3.3 MODES OF OPERATION

The operational software responds to various inputs.These inputs come from the temperature and pressuresensors, the temperature set point, the settings of

Documents

Compressor carrier